Clips for connecting panels and cross members without visual reference

ABSTRACT

Self aligned clips connecting panels, such as solar panels, and cross members are disclosed. An upper clip portion has opposed alignment legs extending downwardly from an upper portion surface that are used to align an opening of the upper portion with a wall fastener housing of the lower portion used with a fastener to connect the upper and lower portions. Remaining fastener housings of the lower portion are used with fasteners to connect the lower portion of the clip to a support member. The lower portion has a space in between a pair of arms receiving the support member. A length between the opposed legs is slightly longer than a length of the wall of the lower portion allowing a user to place the pair of opposed legs just past opposed outer ends of the wall. In use, the lower portion is first installed on the support member with fastener housings and fasteners. The panel is butted against the lower portion and clamped into place when the upper portion is connected to the lower portion. The clip allows for connecting panel and cross members in a “blind” manner as the clip is self aligned.

TECHNICAL FIELD

The invention relates to devices for connecting panels and cross members and, in particular, to clips for connecting panels and cross bars.

BACKGROUND ART

Solar energy systems are an environmentally friendly way of generating electricity. To provide such solar energy, typically there are solar panels which comprise a plurality of solar modules. The solar panels are typically coupled together and secured to a roof of a building, ground, or other structure via supporting cross members using clips or other securing mechanisms.

Since solar panel output is dependent on the amount of sunlight exposure, it is critical that solar panels are positioned properly. Thus installation of the solar system can be difficult. Typically, the solar panels are connected to each other as well as to supporting cross members which generally are supported on a roof or other surface. Alignment of the solar panels to each other and to the supporting cross members is time consuming and tedious.

Examples of panel clips or other securing mechanisms are described below. U.S. Pat. No. 4,966,631 to Matlin et al. describes cushioned load springing attachments securing photovoltaic modules to spanning members. U.S. Publication No. 2006/0086382 to Plaisted describes a mounting system for solar modules with a compressible retention structure for solar modules. U.S. Pat. No. 6,672,018 to Shingleton describes clips used to clamp solar panels to support members having a generally T-shaped profile and a retainer in the form of a channel nut or bar with a threaded hole that receives a bolt or similar threaded fastener. U.S. Pat. No. 5,563,450 to Bader et al. describes a spring grounding clip for a computer peripheral card. U.S. Pat. No. 3,039,569 to Bohnsack describes locking members for a plurality of panels in a partition wall construction. U.S. Pat. No. 4,827,539 to Kiziah describes an adjustable closet floor flange.

Though many different types of securing mechanisms, including clips for securing panels, are known in the art it is an object of this invention to provide an improved clip that would assist in the alignment of panels, such as solar panels, and thus with panel installation.

It is a further object of the present invention to provide clips for connecting panels and cross members.

It is an additional object of the present invention to provide a self aligned clip.

It is another object of the present invention to provide a self aligned clip that can be installed relatively easily without visual reference or in a “blind” fastening manner.

SUMMARY OF THE INVENTION

A self aligned clip connecting panels, such as solar panels, and cross members is disclosed. An upper portion of the clip has a space on either side shaped to receive and align with a portion of a panel. The upper portion also has a channel formed from a flat bottom surface and first and second opposed walls perpendicular to the flat bottom surface, and a pair of opposed ledges, each ledge extending perpendicularly or substantially perpendicularly from one of the perpendicular walls and away from the channel to form the panel receiving spaces. The upper portion also has a pair of opposed alignment legs extending downwardly from the upper portion that are used to align an opening of the upper portion with a fastener housing of a wall of the lower portion used to connect the upper and lower portions at a desired height to accommodate panels of varying heights. A fastener, such as a screw or a bolt, inserted within the opening/through hole and fastened at a desired location within the fastener housing (for example, with a floating nut) connects the upper and lower portions. Remaining fastener housing(s) of the lower portion are used in conjunction with fasteners, such as self drilling/tapping screws to connect the lower portion of the clip to the support member. The lower portion has at least one pair of opposed arms extending downwardly from an upper surface that spans a width of the support member. A space in between the arms receives a portion of the support member. A length between the opposed legs of the upper portion is slightly longer than a length of the wall of the lower portion allowing the pair of opposed legs to extend just past opposed outer ends of the wall when a user engages the upper portion with the lower portion. Typically, the opposed legs contact or abut against opposed outer ends of the wall when the upper portion engages the lower portion. Thus vertical alignment of the opening and one of said fastener housings occurs when the upper portion engages the lower portion as opposed wall ends prevent opposed alignment legs from being laterally moved a distance that positions the opening and the fastener housing out of vertical alignment when the opposed alignment legs are positioned outside of the opposed wall ends thereby vertically self-aligning one of the fastener housings and the opening. The self alignment features or “blind” fastening mechanism of the clip of the present invention allow for panel installation that is less time consuming than the prior art as the clip of the present invention allows alignment of the panels and support members to occur easily.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a clip of the present invention.

FIG. 1B is a front perspective view of the clip of FIG. 1A.

FIG. 1C is a side perspective view of the clip of FIG. 1A.

FIG. 1D is a top view of an upper portion of the clip of FIG. 1A.

FIG. 1E is a top view of a lower portion of the clip of FIG. 1A.

FIG. 1F is an exploded view of the clip of FIG. 1A.

FIG. 2 is a perspective view of a plurality of clips shown in FIG. 1A connecting panels and cross bars.

FIG. 3 is a magnified view of a section of FIG. 2.

FIG. 4 is a view of another embodiment of the lower portion of the clip of the present invention.

FIG. 5 is a view of a different embodiment of the lower portion of the clip of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1A-1C there is seen a clip 10 a of the present invention shown in a clip engaged position and having an upper portion 12 and a lower portion 14. Various types and combinations of materials may be used to construct the clip. For example, the upper and lower portions of the clip may be constructed from stainless steel or cold rolled steel. Also, each portion may be coated for rust protection. The upper portion 12 comprises a channel 16 formed by a flat bottom surface 18 and first and second opposed walls 20, 22 perpendicular or substantially perpendicular to the flat bottom surface 18. Ledge 24 extends substantially perpendicularly or perpendicularly from wall 20 and away from the channel 16. Ledge 26 opposes ledge 24 and extends substantially perpendicularly or perpendicularly from wall 22 and away from the channel 16. For example, when extending substantially perpendicularly each ledge may form an angle slightly less than 90° (for example, no more than 10° less than 90°) with its corresponding wall. Spaces 28, 30 (FIG. 1B) are formed by the ledges and walls and are positionable to receive a portion of a panel. Table 34 with, for example, a generally U-shaped cross section, has a flat upper surface 36 and first and second alignment legs 38, 40 each extending downwardly from the flat upper surface 36. The alignment legs may be perpendicular or substantially perpendicular to flat upper surface 36. Flat upper surface 36 is disposed upon flat bottom surface 18. Table 34 may be attached to or separable from flat bottom surface 18. Opening 42 (FIG. 1F) is disposed through both the flat bottom surface 18 and the flat upper surface 36. In another embodiment, the flat upper surface 36 of the table is not present and legs 38, 40 may extend directly from flat bottom surface 18.

Referring to FIGS. 1D-1F, lower portion 14 of the clip 10 a is connectable to the upper portion 12 and to a cross member 44 a (FIG. 2) at an adjustable height dependent upon the height of the panel to be engaged. Lower portion 14 has opposed pairs of arms 46, 48 each separated by a flat upper surface 50 and 52, respectively. Each flat upper surface has a length that spans the width of the cross member 44 a (FIG. 2) which is, for example, a cross bar or a cross beam. The arms extend downwardly from upper surface 58 a to sides 54 a, 56 a respectively of member 44 a (FIGS. 2-3). A wall 60 is disposed above arm pairs 46, 48 and flat upper surfaces 50, 52. Wall 60 is typically disposed in between flat upper surfaces 50, 52. Wall 60 may be integral with or attachable to flat upper surfaces 50, 52. The wall has opposed outer ends 62 and 64. In the example shown, opposed outer ends 62, 64 extend in both directions perpendicularly past a central portion 65 (FIG. 4) of the wall to form a wall having an H-shaped cross section.

In another embodiment as seen in FIG. 4, a lower portion of the clip includes only one pair of arms 49 with a flat upper surface 51 separating the arms. Wall 61 having fastener housings 63, 65, 67 is disposed atop and generally in the middle of upper surface 51. Wall 61 may be integral with or attachable to upper surface 51.

In another embodiment as seen in FIG. 5, surface 50 of lower portion 14 of the chip includes a grounding burr 76.

Referring to FIGS. 1E-1F, wall 60 is shown to have three fastener housings 66, 68, 70 in a row but may include a greater or lesser number. Fastener housings extend through wall 60. Typically, at least two fastener housings are required, one fastener housing to connect the upper portion of the clip to the lower portion and one fastener housing used to connect the lower portion of the clip to the cross member. In this example, three fastener housings are shown. The fastener housings 66, 68, 70 each comprise a through hole. Referring to FIG. 1F, fastener housing 68 is used to connect the upper portion 12 of the clip 10 to the lower portion 14. A fastener, such as a screw or a bolt, is secured at variable positions within the fastener housing thus allowing for an adjustable height of the upper portion when secured to the lower portion dictated by the thickness of the panel. The desired height is typically achieved with various fastener lengths. The fastener housing used to connect the lower portion of the clip to the upper portion of the clip, in this example, fastener housing 68, is placed into vertical alignment with opening 42 when the upper portion of the clip engages the lower portion. Floating nut 69 (FIGS. 1A-1C) is an attachment mechanism on lower portion of the clip to which fastener 72 fastens. Floating nut 69 has threads used to secure a position of fastener 72. Floating nut 69 is held within an opening (not shown) within vertical wall 60 and typically remains within the same vertical position. The opening extends slightly beyond housing 68 into vertical wall 60. Remaining fastener housings 66, 70 are used to fasten the lower portion of the clip 14 to the cross member 44 a. Fastener housings may be of a cylindrical shape or other shape.

Fasteners, such as self drilling or self tapping screws, in conjunction with the fastener housings 66, 68, 70 are used to connect the upper portion 12 of the clip 10 to the lower portion 14 and the lower portion to the cross member 44 a. In one example, a screw 72 (FIG. 1F) is variably positionable through the opening 42 and is inserted through fastener housing 68 to connect the upper portion 12 to the lower portion 14. Arrangements of nuts and bolts or self drilling or self tapping screws 74 a, 74 b (FIG. 3) may be used to connect the lower portion 14 to the cross member 58 a via remaining fastener housings 66, 70, respectively. Other types of fasteners may also be used.

In using clips to secure panel 32 a (FIG. 2) to cross members 44 a, 44 b, and to another panel 32 b, lower portion of one clip 10 a is secured at a desired position to cross member 44 a using fastener housings 66, 70 and fasteners. Arms 46, 48 of lower portion 14 are sufficiently spaced apart and may be contoured or bent so as to extend over top surface 58 a to contact side surfaces 54 a, 56 a of member 44 a. In this way, the lower portion of the clip is aligned and fastened to the member 44 a. Panel 32 a is then “butted” up against the mounted lower portion of clip 10 a. Opposed outer ends 62 and 64 space panels 32 a, 32 b apart the appropriate distance. Panel 32 a can now be clamped in place using upper portion 12 of the clip. Upper portion 12 of clip 10 a is self-aligned with the secured lower portion. The flat upper surface 36 of the table has a length slightly longer than the length of the wall 60 allowing the user to place the opposed table alignment legs 38, 40 in a position that extends just past opposed outer ends 62, 64 of the wall, respectively, as seen in FIG. 3. When placing upper portion 12 over lower portion 14, vertical alignment of opening 42 (FIG. 1F) and fastener housing 68 is easily achieved as opposed wall ends 62, 64 prevent opposed alignment legs 38, 40 from being laterally moved a distance that positions the opening 42 and fastener housing 68 out of vertical alignment when the user positions the opposed alignment legs outside of the opposed wall ends thereby self aligning fastener housing 68 to the opening 42. Typically, when the user positions the opposed legs outside of the opposed outer ends of the wall, the opposed legs abut the outer ends as seen in FIG. 3. Although, in one embodiment, a small amount of lateral movement of the legs may be allowed to occur without positioning the opening outside of vertical alignment with fastener housing 68. Upper portion 12 of the clip is fastened to the lower portion 14 and panel 32 a is received within space 28 (FIG. 1B) as shown in FIGS. 2 and 3. As described previously, the panel may be clamped into place using a fastener (for example a screw or a large machine threaded bolt) inserted through the through hole of fastener housing/boss 68. Also, as stated previously, spaces 28, 30 are shaped to receive a desired panel. Thus, the clip may be used for clamping almost any thickness of panel and can be installed without visual reference or in a “blind” fastening manner.

As shown in FIG. 2, several clips 10 a-10 f may be used to secure panels to cross members and to other panels. Clips 10 c and 10 d are shown receiving both panels 32 a, 32 b and connecting panels 32 a, 32 b and support members 44 a, 44 b. Clips 10 a, 10 b, 10 e, 10 f, each have a space available to receive a panel. Various arrangements of clips, panels, and cross members may be used to connect panels and cross beams. For instance, a desired number of support beams, clips and panels may be used in a desired configuration. 

1. A clip for connecting panels on a cross member, comprising: an upper portion having a channel comprised of a flat bottom surface and first and second opposed walls, a pair of opposed ledges, each ledge extending outwardly from one of said walls and away from said channel and forming a space with said one of said walls positionable to receive a portion of a panel, a table of a generally U-shape cross section having a flat upper surface disposed on said flat bottom surface and a pair of opposed alignment legs each extending downwardly from said flat upper surface, and an opening disposed through both of said flat bottom surface and said flat upper surface; a lower portion connectable to said upper portion and to a cross member, the lower portion having two pairs of opposed arms, each pair separated by a flat upper surface having a length that spans a width of said cross member, said arms of each pair extending downwardly from opposing ends of said flat upper surface, a wall disposed atop said flat upper surfaces between said arm pairs, said wall having opposed outer ends and at least two fastener housings in a row, wherein said flat upper surface of said table has a length longer than said wall allowing said pair of opposed legs to extend just past said opposed outer ends of said wall, and wherein vertical alignment of said opening and one of said fastener housings occurs when said upper portion engages said lower portion as opposed wall ends prevent opposed alignment legs of said table from being laterally moved a distance that positions said opening and said fastener housing out of vertical alignment when the opposed alignment legs are positioned outside of said opposed wall ends thereby self aligning one of said fastener housings said opening; and at least two fasteners, wherein one fastener is receivable within said opening and an adjustable position in said fastener housing in vertical alignment with said opening thereby connecting said upper portion to said lower portion at an adjustable position, and wherein another fastener is receivable within said other fastener housing, said fastener receivable within said other fastener housing positionable within said cross member thereby connecting said lower portion to said cross member.
 2. The clip of claim 1 wherein three fastener housings are disposed in said row and three fasteners are receivable within said three fastener housings and wherein said fastener housing disposed in between said other two fastener housings is positionable into vertical alignment with said opening.
 3. The clip of claim 1 wherein said fastener housings comprise through holes and wherein said fasteners are self drilling screws or self tapping screws.
 4. The clip of claim 1 wherein said fastener housings are cylindrical.
 5. The clip of claim 1 wherein said fasteners are nuts and bolts.
 6. The clip of claim 1 wherein said opposed outer ends of said wall extend outwardly and perpendicularly from said wall such that said wall has a generally H shape in cross section.
 7. The clip of claim 1 wherein when said opening and one of said fastener housings are in vertical alignment each of said table legs abuts against opposed ends of said wall.
 8. The clip of claim 1 wherein said table is separable from said channel.
 9. The clip of claim 1 wherein said table is attached to said channel.
 10. The clip of claim 1 wherein said wall is disposed along said flat upper surface and in between said pairs of opposed arms.
 11. The clip of claim 1 wherein each arm is contoured so as to extend over a top surface of the cross member to cross member side surfaces.
 12. A clip for connecting panels, comprising: an upper portion having a channel with an opening extending therethrough and first and second elongated ledges, one ledge extending outwardly from said channel and positioned to form an angle slightly less than a right angle with a first side of said channel, and another ledge extending outwardly from said channel and positioned to form an angle slightly less than a right angle with a second side of said channel opposing said first side, and a pair of opposed alignment legs, each alignment leg extending downwardly and perpendicularly from said channel; and a lower portion having a pair of arms with a length in between said arms allowing said arms to extend past a top surface of a cross member and to contact side surfaces of said cross member, said lower portion having a wall of fastener housings disposed atop said length between said pair of arms, wherein one of said fastener housings of said wall is vertically alignable to said fastener opening of said channel and wherein said length between said opposed alignment legs is such that when said lower portion is fastened to said upper portion each of said opposed alignment legs abut one of two opposed outer ends of said wall.
 13. The clip of claim 12 wherein said opposed outer ends of said wall extend outwardly and perpendicularly from said wall such that said wall has a generally H shape in cross section.
 14. The clip of claim 12 further comprising fasteners, wherein one fastener is receivable within said opening and said fastener housing in vertical alignment with said opening and another fastener is receivable within said other fastener housing.
 15. The clip of claim 14 wherein said fasteners are screws.
 16. The clip of claim 14 wherein said fasteners are nuts and bolts.
 17. The clip of claim 14 wherein one of said fasteners is secured at a desired position by a floating nut.
 18. The clip of claim 12 wherein there are three fastener housings extending through said wall and wherein said fastener housing in vertical alignment with said opening is disposed in between the other two fastener housings.
 19. The clip of claim 12 wherein said fastener openings extend through an entire width of said wall.
 20. The clip of claim 12 wherein said lower portion includes a grounding burr disposed on a surface between said pair of arms.
 21. A clip for connecting panels, comprising: an upper portion having opposed spaces at either end of said upper portion shaped to receive a panel, said upper portion also having a channel comprised of a bottom surface with an opening therethrough and alignment legs each extending perpendicularly and downwardly from said bottom surface; a lower portion having a space shaped to receive a cross member and a having a central wall of fastener housings, wherein one fastener housing is in vertical alignment with said opening when said upper portion is connected to said lower portion; and fastening means, wherein one fastening means is receivable within one fastener housing and said cross member and another fastening means is receivable within said opening and a variable position in another fastener housing positionable into vertical alignment with said opening, and wherein said alignment legs are positionable outside of and in an abutting relationship with outer ends of said wall whereby in said position said opening is aligned with said fastener housing positionable into vertical alignment with said opening. 